Apparatus for production of three dimensional objects by stereolithography

• US 6,027,324 A
• Filed: 07/13/1998
• Issued: 02/22/2000
• Est. Priority Date: 08/08/1984
• Status: Expired due to Fees

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Hull, Charles W.
• Primary Examiner(s): DAVIS, ROBERT B
• Application Number:
  US09/114,608
• Time in Patent Office: 589 Days
• Field of Search: 425/174.4, 264/401
• US Class Current: 425/174.4
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/0833 using actinic light
• CPC Class Codes: B29C 2035/0844 using X-ray
• CPC Class Codes: B29C 2035/0877 using electron radiation, e.g. beta-rays
• CPC Class Codes: B29C 35/0866 using particle radiation
• CPC Class Codes: B29C 41/20 incorporating preformed parts or layers, e.g. moulding inserts or for coating articles
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29K 2995/0073 smooth
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: G03F 7/0037 Production of three-dimensional images
• CPC Class Codes: G03F 7/70416 2.5D lithography
• CPC Class Codes: G05B 2219/49013 Deposit layers, cured by scanning laser, stereo lithography SLA, prototyping
• CPC Class Codes: G05B 2219/49017 DTM desktop manufacturing, prototyping
• CPC Class Codes: G09B 25/00 Models for purposes not provided for in G09B23/00, e.g. full-sized devices for demonstration purposes model vehicles, tracks therefor, models in the nature of toys A63H
• CPC Class Codes: G09B 25/02 of industrial processes; of machinery
• CPC Class Codes: Y10T 156/17 Surface bonding means and/or assemblymeans with work feeding or handling means

Abstract

A system for generating three-dimensional objects by creating a cross-sectional pattern of the object to be formed at a selected surface of a fluid medium capable of altering its physical state in response to appropriate synergistic stimulation by impinging radiation, particle bombardment or chemical reaction, successive adjacent laminae, representing corresponding successive adjacent cross-sections of the object, being automatically formed and integrated together to provide a step-wise laminar buildup of the desired object, whereby a three-dimensional object is formed and drawn from a substantially planar surface of the fluid medium during the forming process.

Claims

1. An apparatus for producing a three-dimensional object with a medium capable of a physical state alteration when subjected to prescribed stimulation, said apparatus comprising:

a. means for providing said medium;

b. means for said physical state alteration of said medium to form a lamina integral with any previously formed laminae;

c. means for repeatedly operating (b) to form said three-dimensional object from a plurality of adhered laminae; and

d. means for reorientation of at least one of the laminae before formation of a subsequent lamina.

2. The apparatus as recited in claim 1 wherein the means for said physical state alteration of said medium comprises a means for solidifying the medium.

3. The apparatus as recited in claim 1 additionally comprising:

e. means for forming a layer of said medium in preparation for forming said lamina of said object; and

f. means for operating (e) preceding each operation of (b) to form said three-dimensional object from said plurality of adhered laminae.

4. The apparatus as recited in claim 1 wherein said medium comprises a photopolymer and wherein said means for altering comprises a source of prescribed radiation.

5. The apparatus as recited in claim 3 wherein the means for said physical state alteration of said medium comprises a means for solidification of the medium.

6. An apparatus for producing a three-dimensional object from a plurality of successively formed laminae, said apparatus comprising:

a. means for providing a medium capable of a physical state alteration when subjected to prescribed stimulation;

b. means connected to said apparatus for performing said physical state alteration to form said lamina of said object from said medium integral with any previously formed lamina;

c. means connected to said apparatus for repeatedly operating (b) to form said three-dimensional object; and

d. means for rotating at least one of the laminae before formation of a subsequent lamina, said means being connected to said apparatus and cooperative with said means for performing physical state alteration.

7. The apparatus as recited in claim 6 wherein the means for forming comprises a means for solidification of the medium.

8. The apparatus as recited in claim 6 additionally comprising:

e. means for forming a layer of said medium in preparation for forming said lamina of said object; and

f. means for operating (e) preceding each operation of (c) to form said three-dimensional object.

9. The apparatus as recited in claim 6 wherein said medium comprises a photopolymer and wherein said means for altering comprises a source of prescribed radiation.

10. The apparatus as recited in claim 8 wherein the means for forming said lamina comprises a means for solidification of the medium.

11. An apparatus for producing a three-dimensional object with a medium capable of a physical state alteration when subjected to prescribed stimulation, said apparatus comprising:

a. a container for holding said medium;

b. a source of said prescribed stimulation wherein

a combination including the prescribed stimulation and the medium result in said physical state alteration of the medium, and wherein

the altered portions of the medium form successive laminae integral with any previously formed laminae, and wherein

said three-dimensional object is formed from a plurality of adhered laminae; and

c. a device to reorient at least one of the laminae before formation of a subsequent laminae.

12. The apparatus as recited in claim 11, additionally comprising:

d. a platform to move a previously formed lamina relative to a surface of said medium in preparation for forming an additional lamina of said object;

e. a device to apply said prescribed stimulation to said surface of the medium to form said additional lamina integral with the previously formed lamina; and

f. a computer programmed to repeatedly operate (d) and (e) to form said three-dimensional object from said plurality of adhered laminae.

13. The apparatus as recited in claim 11 wherein said source of prescribed stimulation of said medium comprises a source for solidification of the medium.

14. The apparatus as recited in claim 11 wherein said medium comprises a photopolymer and wherein said source of prescribed stimulation comprises a source of prescribed radiation.

15. The apparatus as recited in claim 12 wherein said source of prescribed stimulation of said medium comprises a source for solidification of the medium.

16. An apparatus for producing a three-dimensional object, said apparatus comprising:

a. a container for holding a medium capable of a physical state alteration when subjected to prescribed stimulation;

b. a source of said prescribed stimulation cooperative with said container and the medium wherein

a combination including the prescribed stimulation and the medium result in said physical state alteration of the medium, and wherein

the altered portions of the medium form a first lamina and successive laminae integral with any previously formed laminae, and wherein

said three-dimensional object is formed from a plurality of adhered laminae; and

c. a device to rotate at least one of the first lamina and/or successive laminae before formation of a subsequent lamina, the device being cooperative with the container and the source of prescribed stimulation.

17. The apparatus as recited in claim 16 wherein said device to rotate moves a previously formed lamina relative to a surface of said medium in preparation for forming an additional lamina of said object, and additionally comprising:

d. a device to apply said prescribed stimulation to said surface of the medium to form said additional lamina integral with any previously formed lamina; and

e. a computer programmed to repeatedly operate said device to rotate and said application device to form said three-dimensional object from said plurality of adhered laminae.

18. The apparatus as recited in claim 16 wherein said source of prescribed stimulation of said medium comprises a source for solidification of the medium.

19. The apparatus as recited in claim 16 wherein said medium comprises a photopolymer and wherein said source of prescribed stimulation comprises a source of prescribed radiation.

20. The apparatus as recited in claim 17 wherein said source of prescribed stimulation of said medium comprises a source for solidification of the medium.

21. An apparatus for producing a three-dimensional object with a medium capable of solidification, said apparatus comprising:

a. a device to provide said medium in a fluid state;

b. a computer controlled device to form successive laminae from said fluid medium; and

c. a device to reorient at least one of the laminae before formation of a subsequent lamina, wherein

said three-dimensional object is formed from a plurality of adhered laminae.

22. An apparatus for producing a three-dimensional object, said apparatus comprising:

a. a device to provide a medium in a fluid state that is capable of solidification;

b. a computer controlled device to form at least one lamina from said fluid medium, integral with any previously formed laminae; and

c. a device to rotate at least one of the laminae before formation of a subsequent lamina, wherein

said three-dimensional object is formed from a plurality of adhered laminae.

23. An apparatus for producing a three-dimensional object, said apparatus comprising:

a. a device to provide a medium capable of an alteration when subjected to prescribed stimulation;

b. a computer controlled source of said prescribed stimulation wherein

a combination including the prescribed stimulation and the medium result in an alteration of the medium so as to define successive laminae; and

c. a device to reorient at least one of the laminae before formation of a subsequent lamina, wherein

said three-dimensional object is formed from a plurality of successive laminae.

24. An apparatus for producing a three-dimensional object, said apparatus comprising:

a. a device to provide a medium capable of an alteration when subjected to prescribed stimulation;

b. a computer controlled source of said prescribed stimulation wherein

a combination including the prescribed stimulation and the medium result in said alteration of the medium so as to define a first lamina and successive laminae integral with any previously formed laminae; and

c. a device to rotate at least one of the laminae before formation of a subsequent lamina, wherein

said three-dimensional object is formed from a plurality of successive laminae.